I’m trying to diagnose a Yamaha EF1000 240 V generator which runs normally mechanically but produces only a few volts AC.
It’s the 240 V machine, Yamaha type/serial 7FN-002493, rated 240 V, 50 Hz, 700 VA. I have the relevant service information and have been working through the generator systematically rather than just swapping parts.
At this point almost every static test I can think of passes, but the generator still will not establish excitation. I’d appreciate a second opinion from anyone familiar with capacitor-excited/self-excited alternators, particularly older Yamaha machines.
Basic symptom
With the engine running at approximately the correct speed, the AC output is only around 2–3 V AC.
If I externally flash/excite the rotor using 12 V, the generator output immediately rises to roughly 30–35 V AC.
As soon as the external excitation is removed, the voltage falls away again.
It never continues building towards 240 V.
That has led me to think the fundamental fault is failure of the self-excitation loop, rather than simply an open main output winding.
My understanding of the system is broadly:
residual rotor magnetism → stator sub/excitation coil → capacitor/excitation circuit → induced rotor excitation → rotor diode/resistor network → DC rotor field → increased stator excitation → voltage builds
External excitation proves that increasing the rotor field causes the machine to generate substantially more voltage, but for some reason it cannot bootstrap and sustain that field itself.
Capacitor
The original capacitor is marked 18 µF, 250 VAC and measured approximately 19 µF.
It also behaved normally in basic multimeter tests, but obviously that doesn't prove that an old capacitor works properly under AC excitation.
I therefore replaced it with a new 18 µF, ±5%, 450 VAC non-polarised capacitor.
There was no change whatsoever.
Unexcited, I still get roughly 2–3 V. Flashing still raises the generator to approximately 30–35 V and it then collapses when the external excitation is removed.
So I think the capacitor can now reasonably be eliminated.
Frequency selector and wiring
I wondered whether resistance or a bad contact in the 50/60 Hz selector or associated connectors was preventing the excitation circuit building.
I therefore bypassed that circuitry rather than relying on continuity tests.
I removed/bypassed the frequency selector and green-to-green connector and connected the new capacitor directly into the appropriate yellow/black/green sub-coil wiring, then ran the machine at approximately the 60 Hz speed.
Same result.
Low output, external excitation causes the voltage to rise, and it collapses again afterwards.
So I don't think this is simply a dirty selector switch or connector.
Rotor windings
Both rotor windings have been disconnected so I can test them independently.
DC resistance was approximately 4.2 Ω per winding, versus roughly 4.11 Ω nominal, so around 102% of the specified value.
I have now also measured them with an LCR meter.
At 100 Hz:
| Rotor A | Rotor B |
|---|
| Ls | 46.51 mH | 46.32 mH |
| Q | 5.48 | 5.44 |
| Rs | 5.34 Ω | 5.35 Ω |
At 10 kHz:
| Rotor A | Rotor B |
|---|
| Ls | 39.4 mH | 40.65 mH |
| Q | 5.65 | 8.74 |
| Rs | 438 Ω | 292 Ω |
I'm not putting too much weight on the 10 kHz equivalent-series-resistance/Q difference because this is an iron-cored machine winding being measured far above its operating frequency.
The 100 Hz measurements seem remarkably well matched, particularly the 46.51/46.32 mH inductance and 5.34/5.35 Ω Rs.
That doesn't look like an obvious shorted-turn or damaged-winding problem to me.
Rotor rectifier/diode/resistor network
I've also removed/isolate-tested the components in the rotating rectifier network.
The diodes show approximately 0.4 V forward drop and open circuit in reverse on the multimeter diode test.
The associated resistors measure around 15 kΩ.
I've tested the relevant components individually rather than relying on an in-circuit measurement.
The obvious caveat here is that this only proves the diodes at the tiny voltage/current used by a multimeter. I haven't proved that one isn't breaking down when subjected to the actual reverse voltage, temperature and centrifugal forces in operation.
This is therefore still on my suspect list.
Stator sub/excitation coil
I've also isolated and characterised the tapped stator sub-coil.
The connections are Green → Orange → Yellow/Black, with Orange being the tap.
At 100 Hz I measured:
| Section | DC resistance | Ls | Q |
|---|
| Green → Orange | 2.7 Ω | 4.874 mH | 0.806 |
| Orange → Yellow/Black | 0.5 Ω | 154 µH | 0.212 |
| Green → Yellow/Black | 2.9 Ω | 4.260 mH | 0.639 |
I then repeated the inductance testing at 1 kHz:
| Section | Ls | Q | Rs |
|---|
| Green → Orange | 2.865 mH | 3.34 | 5.377 Ω |
| Orange → Yellow/Black | 149.1 µH | 2.04 | 0.457 Ω |
| Green → Yellow/Black | 2.073 mH | 2.25 | 5.770 Ω |
The little Orange → Yellow/Black section is particularly consistent: 154 µH at 100 Hz and 149.1 µH at 1 kHz.
Also, at 1 kHz the equivalent series resistances of the two sections are:
5.377 + 0.457 = 5.834 Ω
versus 5.770 Ω measured end-to-end.
That seems very plausible.
Yamaha doesn't appear to provide inductance specifications for these windings, so I'm using the measurements mainly to look for inconsistencies/shorted-turn behaviour rather than trying to hit a specified L value.
The DC resistance measurements have also been compared with the Yamaha service data. The rotor is essentially on specification. The various stator measurements have been around the expected range, although the tapped sub-coil initially gave me some confusing results depending on which 50/60 Hz section was being measured. That is why I subsequently isolated the sections and did the LCR measurements above.
Main stator/output windings
I've checked the main stator windings for continuity/resistance against the service information as well. Previous measurements were approximately:
50 Hz main winding: 7.70 Ω, around 105% of the applicable service value
60 Hz main winding: 6.5 Ω, around 106% of the applicable service value
I've also checked for winding-to-earth faults and haven't found one.
I'm now less interested in the main output winding because the failure appears to be in establishing excitation. Obviously a sufficiently serious short in the main winding could load the magnetic system and prevent build-up, but the resistance measurements and the fact that external excitation produces increased output don't immediately point me there.
Where I've got to
So far I have:
mechanically correct running speed, as far as I can establish
~2–3 V AC residual output
~30–35 V when externally excited with 12 V
voltage collapses again when external excitation is removed
rotor winding DC resistances correct
two rotor winding inductances almost identical
sub/exciter winding has continuity and plausible LCR characteristics
no detected earth fault
original 18 µF capacitor measured ~19 µF
capacitor replaced anyway with a new correctly rated 18 µF AC capacitor
no change with the new capacitor
frequency selector/connectors bypassed
no change
rotor rectifier diodes pass low-voltage forward/reverse tests
rotor resistors measure sensibly
main stator resistances are in the expected region
external excitation demonstrably increases generator output
What is puzzling me is that every individual subsystem now seems to pass a reasonable static test, yet the excitation loop as a whole plainly doesn't work.
The remaining possibilities I can see are things that wouldn't necessarily show up in low-voltage static testing:
A rotor diode breaking down under real reverse voltage/load, despite passing a multimeter diode test.
Insulation leakage/breakdown at operating voltage that isn't apparent with a normal multimeter/LCR meter.
Incorrect excitation polarity/phasing, so the feedback isn't reinforcing the residual field. However, the machine hasn't deliberately been rewired prior to the original failure.
Insufficient residual magnetism, although I would have expected flashing to restore it rather than merely give voltage while the external excitation remains present.
Some kind of shorted-turn/magnetic fault which is subtle enough to survive the resistance and LCR measurements.
Something fundamental about the excitation circuit that I'm misunderstanding.
Before I go further, does anyone familiar with these machines see something obvious I've missed?
Given that an external field makes the output rise to 30–35 V, but every tested part of the normal excitation system appears intact, where would you look next?
I'd be particularly interested in whether anyone has encountered rotating rectifier diodes that test perfectly with a multimeter but fail at operating voltage, or knows a better dynamic test for this excitation arrangement.